Fuel Sender Assembly Replacement for Chevrolet Malibu 2001

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Remove the fuel tank (4). Refer to Fuel Tank Replacement .

Important: 

•	The modular fuel sender assembly may spring up from position.

•	When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The reservoir must be tipped slightly during removal to avoid damage to the float. Discard the fuel sender seal and replace the seal with a new one.

•	Carefully discard the reservoir fuel into an approved container.

2. Press down and rotate the cam lock ring (1) until free of the fuel sender retaining tabs.
3. Remove the modular fuel sender assembly.
4. Remove the fuel level sensor. Refer to Fuel Level Sensor Replacement .

1. Install the fuel level sensor. Refer to Fuel Level Sensor Replacement .



2. Install a new seal on the fuel tank (4).
3. Align the fuel lines parallel with the mark on the fuel tank.
4. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on tank.

Important: Be sure that the cam lock ring is fully seated within the tab slots.

5. Install the cam lock ring.
6. Install the fuel tank (4). Refer to Fuel Tank Replacement .